Autonomous Mechatronic Fabrication With Robotic Part Embedding
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Solution Overview
Problem
Current additive manufacturing (AM) systems require manual intervention for embedding non-printable components and forming electrical connections, limiting the efficiency and flexibility of multi-functional part fabrication, especially in unmanned systems.
Innovation Solution
An autonomous fabrication system with a multi-axis robotic arm equipped with an AM toolhead and a component gripping mechanism enables automated embedding and interconnection of prefabricated parts, allowing for the fabrication of complete mechatronic systems, such as drones, by integrating additive manufacturing and pick-and-place operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual embedding steps are used to place non-printable components, then flexibility in component selection is maintained, but productivity and automation level are reduced
Solution Approach 1:
The system performs embedding operations autonomously without human intervention. The robotic arm automatically picks components from a repository, positions them in the build chamber, and the AM system embeds them during printing, eliminating the need for manual embedding steps while maintaining component selection flexibility through programmable control
Solution Approach 2:
Components are pre-positioned in a repository with standardized interfaces before the embedding process begins. The system pre-plans the embedding sequence and pre-positions components according to the design model, enabling automated high-speed fabrication while maintaining adaptability through programmable reconfiguration
2Adaptability or versatility
If manual embedding steps are used, then complex geometries can be accommodated, but device complexity and operation difficulty increase
Solution Approach 1:
The system employs a universal standardized interface design for all components, allowing the same robotic arm and embedding process to handle diverse components including non-printable parts, electronics, and structural elements. This multi-functional approach accommodates complex geometries while simplifying operation through standardized procedures
Solution Approach 2:
Manual mechanical embedding operations are replaced with an automated robotic system controlled by software. The robotic arm with gripper mechanism substitutes human hands, and programmable control replaces manual skill, enabling complex embedding sequences to be executed automatically while maintaining geometric flexibility
3Extent of automation
If hybrid AM systems with Pick and Place assembly are implemented, then automation level increases, but device complexity and initial cost increase
Solution Approach 1:
The Pick and Place assembly system is merged with the additive manufacturing system into a single integrated platform. The robotic arm operates within the AM build chamber, and both processes are coordinated by a unified control system, reducing overall system complexity compared to separate standalone systems while maintaining high automation
Solution Approach 2:
The robotic arm serves multiple functions: it positions components for embedding, manipulates materials during printing, and performs post-processing operations. This multi-functionality reduces the number of separate devices needed, simplifying the overall system architecture while maintaining high automation levels
4Reliability
If human intervention is required for embedding, then quality control can be performed manually, but productivity and time consumption are reduced
Solution Approach 1:
The system incorporates sensors and vision systems that provide real-time feedback during the embedding process. The robotic arm uses vision guidance to locate components and verify positioning, while the control system monitors embedding quality and makes adjustments automatically, maintaining high reliability without sacrificing speed
Solution Approach 2:
Manual quality inspection is replaced with automated optical inspection systems and sensor-based verification. The system automatically detects positioning errors, component orientation issues, and embedding defects, maintaining quality control reliability while enabling high-speed automated fabrication without human intervention delays
Data Source
AI summary
An autonomous fabrication method and system are described. A multi-axis robotic arm having at least one end effector is provided, where the at least one end effector comprises an additive manufacturing (AM) toolhead and a component gripping mechanism. The multi-axis robotic arm is directed to fabricate a first portion of an object in a workspace using the AM toolhead, select a prefabricated part using the component gripping mechanism, place the prefabricated part in a predetermined location of the object, and fabricate a second portion of the object in the workspace using the AM toolhead. The object may be one of an unmanned aerial vehicle and an unmanned ground-based vehicle.